Custom Power Supplies
Rugged power converters made in the USA to your specifications
BEAR excels at custom power supply design and manufacturing.
We specialize in meeting your most unusual requirements:
hard-to-meet electrical specs, unusual features or form factors,
very long life or extreme operating temperature ranges, or
whatever you can throw at us. Try us!
From mW to KW, we create AC/DC, DC/AC or DC/DC converters in
open frame, enclosed or encapsulated packages to suit your
Our custom power converters are compact and rugged. They are designed and built for long life
and reliable operation over a wide operating temperature range.
BEAR custom power supplies are used in a wide range of industrial,
commercial and medical applications including
telecommunications, smart grid, military, transportation,
industrial automation and portable systems.
Why work with BEAR?
First: Expertise. We understand how to make rugged, reliable power supplies.
Second: We're easy to work with. Our engineering and
manufacturing teams work together in one location, conveniently
located in western New York. We focus on understanding your real
needs, offering expert guidance on your specs, and creating
highly manufacturable products.
You'll go from concept to prototype to production -- quickly and cost effectively --
without the communication issues and delays you can experience
with offshore manufacturers.
Our NRE charges are reasonable, and we'll take on custom
power supply jobs with lower production volumes than many other
suppliers. We currently produce custom power supplies in
quantities from 50 to 50 thousand per year in our upstate New
York manufacturing center.
Designed and made in
What can we do for you?
Thinking of using a custom power supply? Browse the gallery
below for a few examples that show how a custom power supply
made sense to meet unusual OEM requirements.
Then give us a call. We'll help you
weigh the benefits of using a custom
power supply in your project. We'll tell you right up front
if you'd be better off using a standard power supply, and why.
directly or use our online
custom power supply RFQ form
to get started.
BEAR custom power supply gallery
50 Watt DC/AC industrial power supply
- Input 40-90 V DC
- 16 kHz AC output
- 1 A output
This high-frequency transformer driver for floating
supplies is used with 3-phase industrial motors, meeting
the customer's unusual requirements for input, output
and frequency. The compact, rugged design measures 3.5 x
2 x 1 inch and features a wide operating temperature
75 Watt dual-output AC/DC medical power supply
- CF rated medical power supply
- Ultra-low capacitance < 15 pF
- Separate BF rated input
This 75 Watt medical power supply
powers a surgical instrument. The CF-rated output
features an ultra-low capacitance of less than 15 pF.
The two outputs can be controlled independently so that
the CF-rated output can be switched off when not needed,
while the BF-rated output remains active to supply
electronics used in the vicinity of a patient. The 8 x
2.5 x 1.25 inch universal-input medical power supply has
very low EMI and is certified to EN 60601-1-2 (revision
2 and revision 3).
40 Watt AC/DC medical power supply
- CF rated medical power supply
- super-capacitor powered alarm circuit
This 40 Watt medical power supply
is used in a life support system. It features a super
capacitor powered alarm circuit to notify users if the
the unit becomes unplugged or loses power.
"BEAR employees are great to work with and very responsive to my needs."
- Bob Lindley, Hardware Design Engineer
15 Watt DC/DC power supply for specialty lighting
- high voltage arc (12,000 V) to start lamp
- switches to constant power to run bulb
- 12 to 24 VDC input
This highly efficient converter for specialty
lighting applications delivers a high-voltage arc to
start an arc lamp, then switches to a constant power
mode for long-term operation. It accepts an input range
of 12 to 24 VDC.
75 Watt combination AC/DC and AC/AC medical power supply
- universal input
- 1 AC output (120 VAC)
- 4 DC outputs (+24 VDC, +12 VDC, +5 VDC, +5 VDC
This power converter has universal input and five
different outputs for AC, DC and isolated DC voltages.
It powers a multi-function medical diagnostic system
that is compact and portable.
15 Watt DC/DC medical power supply
- drives a 15 Watt LED with dimming
- drives variable-speed fan to maintain temperature
- compact 1 x 3" size
This compact, dual-purpose medical power supply
drives a 15 Watt LED with dimming. It also powers a
variable-speed fan to prevent LED overheating. The
microprocessor reads a temperature sensor on the LED and
automatically adjusts fan speed to maintain the
temperature below the set threshold.
BEAR custom power supply production capabilities include fast-turn prototypes,
pre-production runs, and low- to mid-volume manufacturing in
our USA facility.
12 Watt AC/DC power supply for medical
- plugs directly into wall outlet
- rugged: very rigorous drop test; built to withstand
pulling, yanking and impact
- production volume several hundred thousand/year
This rugged "wall wart" power supply was designed for
the rigors of a hospital-based use. It withstands abuse
such as being yanked from the wall and slammed onto the
floor. The sealed and molded package can be disinfected
and washed down with chemicals.
3 Watt DC/DC power supply for LED lighting
- very small
- incorporates microprocessor for dimming
- high efficiency
This compact DC/DC converter is used in a hand-held
LED device and incorporates an LED dimming function in a
very compact size.
"Working with BEAR’s USA-based design and manufacturing team is a
plus. They anticipated our needs, made excellent design
recommendations, and provided fast turn-around."
- Bob Cook, president
75 Watt AC/DC power supply for industrial monitoring
- dual input: universal AC plus 24 VDC
- -40 to +70C full-load operating temperature
- reports output current, output voltage and
temperature over I2C
This dual-input power supply allows an industrial
system to run on AC with auxiliary DC input. The
self-monitoring feature allows the system to query the
supply’s functioning over an I2C bus. As part of an
outdoor transportable measurement system, it features a
wide full-load temperature and high vibration tolerance.
15 KV, 5 Watt DC/DC converter for military
- 15,000 Volt output
- triple outputs, low ripple
- mil spec for shock and vibe
This rugged, triple-output power supply features
extremely high output voltage. Designed for an airborne
military application, the compact converter is
encapsulated in a die-cast aluminum housing and meets
mil specs for shock and vibration.
"We're pleased to be working with [BEAR parent company]
Z-AXIS, which was highly recommended by other groups within
Harris for its quality and on-time delivery."
- Thomas Kenny, vice president of product line
Harris RF Communications
30 Watt AC/DC power supply for utilities
- extreme operating temperature range
- high line surge capacity
- long life
As part of a monitoring system to be mounted on a
utility pole, this power supply will deliver years of
reliable operation under extreme temperatures. It will
also withstand high transient surges such as those
caused by lightning.
660 Watt AC/DC power supply ultra-low leakage
current for medical instruments
- very low leakage current (5
standards for Type CF medical equipment
- 3 isolated outputs
- universal input with PFC front end
This custom medical power supply includes a unique "self-monitoring"
feature with built-in digital reporting of output
voltages, current and operating temperatures. See more
information about our medical
BEAR designs and manufactures custom power supplies
for a wide range of medical, commercial and industrial
180 Watt custom DC/DC converter for ground
- 4,000 VAC input/output isolation
- very long life
- low input and output noise
Designed to meet a requirement for extremely high
input/output isolation, this custom DC/DC converter also
allowed our customer to reduce the size and cost of
their existing system.
850 Watt custom DC/DC converter for mobile
- 3 isolated outputs
- hot-swappable with load sharing
- stringent mechanical constraints
Rugged custom design with specific mechanical
constraints is used in a rack-mounted system in a mobile
With custom power supply design, manufacturing, sales and
support all under one roof, BEAR offers unique advantages in
design for manufacturing (DFM), quality and customer support.
Rack-mounted AC/DC converter for transportation systems
- PFC input / 60W output
- Minimum 10-year life required
- 24/7 operation in a fanless system
- Custom mechanical design
This customer required very high
reliability and long life. They also had specific
mechanical configuration and input connector
300 Watt DC/DC converter for commercial telecom system
- Four different outputs
- Input - 48VDC
- High efficiency
High efficiency allows this unit to be
cooled with a single fan. It replaced an off-shore
manufacturer’s power supply that is less efficient and
required two large cooling fans. BEAR's mechanical design
recommendations allowed our customer to
remove other hardware costs from their system.
"From the initial call, the customer was very impressed with BEAR’s
knowledge and support for custom power supply design."
– Perry Thornton, sales representative
60 Watt AC/DC converter for a portable medical instrument
- High efficiency over very wide input voltage and
- Mechanically rugged
- Entire heat load contained in a sealed unit
- Special input connector allows system to be washed
down and disinfected without leaking or degrading
For this custom medical power supply, BEAR passed stringent testing requirements that the
customer's offshore supplier had been unable to meet.
See more information about our
medical power supplies.
1.5 Watt mini DC/DC converter for portable military communications system
- 100VDC output
- Wide operating temperature range: -55 to +85°C
- High efficiency
- Small size 0.5 x 0.5 x 0.4 inches (12.7 x 12.7 x 10.2 mm)
BEAR now offers this custom supply as a standard configurable product. See our
DC/DC power supplies.
For more information